Modular electrical wiring device system

ABSTRACT

The present invention is directed to a method including the steps of providing a frame member configured to be disposed over a device wall box, the frame member including at least one frame opening having a lip member configured to substantially extend into an interior region of the device wall box, the at least one frame opening being further configured to substantially define a modular space; and providing at least one modular electrical wiring device configured to substantially conform to the modular space in accordance with at least one of a plurality of modular configurations, the at least one modular electrical wiring device being configured to include a plurality of attachment structures configured to mate with the frame member, the at least one modular electrical wiring device being configured to be disposed within the at least one frame opening in an orientation selected from a plurality of orientations including at least one first orientation and at least one second orientation, the at least one first orientation being substantially orthogonal to the at least one second orientation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional of U.S. patent application Ser. No. 15/147,297, filed on May 5, 2016, which is a continuation of U.S. patent application Ser. No. 15/081,028, filed on Mar. 25, 2016, which is a continuation of U.S. patent application Ser. No. 13/680,675, filed on Nov. 19, 2012, the content of each is relied upon and incorporated herein by reference in its entirety, and the benefit of priority under 35 U.S.C. § 120 is hereby claimed, U.S. patent application Ser. No. 13/680,675 claims priority to U.S. Provisional Patent Application Ser. No. 61/635,432, filed on Apr. 19, 2012.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to electrical wiring devices, and particularly to a modular electrical wiring device system.

2. Technical Background

The conventional method for installing electrical circuits includes a “rough-in” installation phase and a finish installation phase. In the rough-in phase, conduit or cable is disposed throughout the structure in accordance with the building plans. Junction boxes are installed at appropriate locations to house electrical connection points where two or more conductors can be spliced together. Device boxes are installed throughout the structure where electrical service is desired. After the boxes are placed, the electrical wires are pulled through the conduits (if provided) and all of the circuits are bonded such that the neutral conductors are connected to ground at or near the circuit breaker.

After the rough-in phase has been completed, the electrical wiring devices are terminated, i.e., they are electrically connected to the wire leads. This part of the installation process is typically performed or supervised by a journeyman electrician. Subsequently, the ground strap of the electrical wiring device is mounted to the device box. One or more electrical wiring devices may be mounted to a device box depending on the size of the device box. A single-gang device box typically accommodates one electrical wiring device, a two-gang device box will typically accommodate two electrical wiring devices, and so on and so forth. Once an electrical wiring device is installed inside the device box, a cover plate is disposed over the electrical wiring device to “complete the electrical enclosure” such that individuals are not exposed to “hot” electrical wiring after the electrical power is turned ON.

Non-limiting examples of electrical wiring devices include electrical receptacles, ground fault circuit interrupters (GFCIs), switches, and dimmers. Other non-limiting examples include night light devices, charging devices, and accent lighting devices. Some wiring devices may include combinations of the device functions listed above.

There are several drawbacks associated with conventional installation methods and conventional wiring devices. Conventional wiring devices often do not make efficient use of space because they are typically sized to fit a single-gang device box, whether they require this space or not. In addition, wire termination and device mounting (i.e., connecting the ground strap to the device box) are tedious, time consuming, and therefore costly procedures. The same can be said of mounting the cover plate to the electrical wiring device. What is needed is an electrical wiring system that addresses these concerns.

Another drawback relates to multi-gang installations. The finished look is often ragged because the plurality of electrical devices and their respective cover plates are typically not in alignment. In fact, the various devices re often misaligned in all three dimensions. What is needed therefore is an electrical wiring system that addresses the above stated misalignment issues.

Retrofitting an electrical installation can also be problematic from a finished look standpoint because the device box (usually an old work box) may not be precisely aligned to the plane of the existing wall surface. This is especially true if the wall surface itself is uneven. There are also safety drawbacks to retrofitting an existing electrical installation. After remodeling is substantially finished, homeowners often seek to replace the existing wall plates with ones that better match the new décor. Thus, a homeowner may inadvisably remove the faceplate cover from an energized wiring device and inadvertently become exposed to a shock hazard from the “hot” electrical wiring. What is needed therefore is a wiring system that protects homeowners and occupants from the risk of shock or electrocution when the cover plate is removed.

SUMMARY OF THE INVENTION

The present invention addresses the various needs described above by providing a rigid frame that “completes the enclosure” while supporting a variety of modular electrical wiring devices. The modular electrical wiring devices of the present invention make efficient use of space by allowing up to three devices to be installed within a single gang device box. In addition, the frame of the present invention eliminates the need for mounting the electrical wiring device to the device box. Moreover, the modular electrical wiring devices of the present invention do not require fasteners to be securely installed within the device box. Because the frame and the modular device(s) disposed therein complete the enclosure, no cover plate is needed. The cover plate is replaced by an aesthetic overlay that can be removed at any time without exposing the homeowner to shock or electrocution. As its name suggests, the aesthetic overlay of the present invention may be comprised of a variety of decorator materials without regard to the structural considerations that are concomitant with completing the enclosure. Finally, because the frame of the present invention completes the enclosure, it may be employed with new construction, old construction or retrofits.

One aspect of the present invention is directed to an electrical wiring system that includes a frame configured to be mounted to a device wall box installed in a structure. The frame includes a first edge formed around a peripheral portion of the frame. The first edge is configured to substantially abut a surface of the structure disposed around the device wall box. The frame assembly further includes a frame opening corresponding to at least one gang opening. The frame opening substantially defines a second edge configured to extend inwardly toward the device wall box interior such that the frame opening provides access to the device wall box interior. At least one modular device is configured to be disposed within the frame opening to complete the system enclosure such that the device wall box interior is substantially inaccessible. The at least one modular device is selected from a group of modular devices that includes at least one modular electrical wiring device and at least one alignment device. An aesthetic overlay is configured to be removably coupled to the frame assembly. The aesthetic overlay includes an overlay opening configured to provide access to at least a portion of the at least one modular device.

In another aspect, the present invention is directed to an electrical wiring system that includes an electrical wiring system that includes a frame configured to be mounted to a device wall box installed in a structure. The frame including a first edge formed around a peripheral portion of the frame, the first edge being configured to substantially abut a surface of the structure disposed around the device wall box. The frame assembly further including a frame opening corresponding to at least one gang opening. The frame opening substantially defines a second edge configured to extend inwardly toward the device wall box interior such that the frame opening provides access to the device wall box interior. At least one modular device is configured to be disposed within the frame opening such that an interior of the device wall box is substantially inaccessible. The at least one modular device is not configured to connect to the device box. The at least one modular device is selected from a group of modular devices that includes at least one modular electrical wiring device and at least one alignment device. The at least one electrical wiring device module is configured to be disposed within the frame opening in a plurality of spatial orientations. The at least one modular electrical wiring device further includes a self-grounding mechanism configured to engage a portion of the frame when the at least one modular electrical wiring device is coupled within the frame opening in any one of the plurality of spatial configurations. An aesthetic overlay assembly is configured to be removably coupled to the frame assembly. The aesthetic overlay assembly includes an overlay opening configured to provide access to at least a portion of the at least one modular device.

Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention and together with the description serve to explain the principles and operation of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B are perspective views of a frame member in accordance with the present invention;

FIGS. 2A-2D are perspective views of a modular alignment connector in accordance with the present invention;

FIG. 3 is a detail view of the modular alignment connector depicted in FIGS. 2A-2D;

FIGS. 4A-4E are illustrative views showing installation details of the frame, modular alignment connector and electrical wiring device;

FIGS. 5A-5D are perspective views of various modular electrical wiring device types in accordance with the present invention;

FIGS. 6A-6N are illustrative views showing various combinations of modular electrical wiring devices installed within a single gang frame member;

FIG. 7 is a perspective view showing a three gang frame member with an illustrative combination of modular electrical wiring devices installed therein;

FIG. 8 is a perspective view of a two gang frame member with a ground wire in accordance with the present invention;

FIG. 9 is a perspective view of a three gang frame member with a ground wire in accordance with the present invention;

FIG. 10 is a perspective view of a four gang frame member with a ground wire in accordance with the present invention;

FIGS. 11A-11B are front views of the three gang and four gang frame members depicted in FIGS. 9 and 10;

FIG. 12 is an exploded view of an aesthetic overlay assembly in accordance with an embodiment of the present invention;

FIG. 13 is an exploded view of an aesthetic overlay assembly in accordance with another embodiment of the present invention;

FIG. 14 is an exploded view of an aesthetic overlay assembly in accordance with yet another embodiment of the present invention;

FIGS. 15A-15D are various views of the modular electrical wiring device system showing the aesthetic overlays depicted in FIGS. 12, 13 and 14;

FIG. 16A is an exploded view of an electrical wiring device comprising a self grounding feature in accordance with the present invention;

FIG. 16B is a detail view of a dual sided ground component depicted in FIG. 16A;

FIG. 17 is a rear view of the modular system illustrating the self grounding feature depicted in FIGS. 16A-16B;

FIG. 18 is a perspective view of one orientation of the self grounding feature of the present invention;

FIG. 19 is a perspective view of another orientation of the self grounding feature of the present invention;

FIG. 20 is a perspective view of yet another orientation of the self grounding feature of the present invention;

FIG. 21 is a four gang embodiment of the modular system employing the self grounding feature in accordance with the present invention;

FIG. 22 is a four gang embodiment of the modular system in accordance with additional embodiments of the present invention; and

FIG. 23 is a three gang embodiment of the frame in accordance with the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to the present exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. An exemplary embodiment of the modular system 100 of the present invention is shown in FIGS. 6, 7, 15 and 17-22, and is designated generally throughout by reference numeral 100.

The reference numerals of the various component parts of the present invention are shown in Table I below.

TABLE I List of Component Parts No. Component No. Sub-component  1 Wall surface  2 Device box  10 Frame 10-1 Frame Front face 10-2 Frame rear side 10-3 Ratcheting overlay snap 10-3′ Overlay removal pry 10-4 Side overlay snap 10-5 Frame enclosure lip 10-6 Interior serrated lip 10-60 Serrated stop elements 10-7 Connector landing 10-8 Ground connection location 10-9 Ground wire 10-10 Wall box fasteners 10-11 Fastener location blanks 10-12 Fastener slots 10-13 Frame opening 10-14 Frame connector seat 10-15 Lateral frame portion 10-20 Two gang frame 10-21 Gang separation ribs 10-30 Three gang frame 10-31 Gang separation ribs 10-40 Four gang frame 10-41 Gang separation ribs  20 Modular alignment connector 20-1 Connector front major surface 20-2 Connector rear major surface 20-3 Bending snap arm 20-4 Spacer tang 20-5 Spacer channel 20-6 Front stabilizing plate 20-7 Rear stabilizing plate 20-8 Connector channel 20-9 Device stop elements  30 One module electrical wiring device 30-1 User interface 30-2 Device snap 30-3 Back body  40 Two module electrical wiring device 40-1 User interface 40-2 Device snap 40-3 Back body 40-4 Separator member 40-5 Shutter member 40-6 Internal device circuitry 40-9 Device ground wire 40-10 Self grounding feature 40-11 Device ground access point 40-12 Ground strap element 40-13 Ground receptacle terminal 40-14 Dual contacts 40-15 Labeling flange 40-16 Receptacle openings  42 Two module front/three module back body electrical wiring device (“two-three electrical wiring device”). 42-1 User interface 42-2 Device snap 42-3 Back body  50 Three module electrical wiring device 50-1 User interface 50-2 Device snap 50-3 Back body  60 Aesthetic Overlay assembly 60-1 Aesthetic overlay plate 60-2 Aesthetic support frame 60-3 Frame support catch 60-4 Frame snap catch 60-5 Snap openings 60-6 Overlay snaps 60-7 Overlay removal catch 60-8 Overlay removal pry 60-10 Aesthetic plate opening  60′ Aesthetic Overlay assembly (FIG. 13) 60-20 Top finish ply 60-21 Frame support plate 60-22 Pressure sensitive adhesive 60-23 Backing plate 60-24 Ground link 60-25 Support posts 60-26 Support post openings 60-27 Backing plate posts 60-28 Frame support post openings  60″ Aesthetic Overlay assembly (FIG. 14) 60-31 Aesthetic overlay support posts 60-32 Post openings 60-33 Robin tails 60-34 Robin tail nests 100 System E.g., frame 10, optional modular connector 20, at least one modular electrical wiring device (30-50), and optional aesthetic overlay assembly 60.

As embodied herein, and depicted in FIGS. 1A-1B, perspective views of a frame member 10 in accordance with the present invention are disclosed. FIG. 1A is directed to the rear side 10-2 of the frame member 10, whereas FIG. 1B is directed to the front side 10-1 of the frame member 10. The frame member 10 is configured to “complete the electrical enclosure” when one or more modular electrical devices (30, 40 or 50) and/or modular alignment connectors 20 are properly installed within the frame opening 10-13 such that the device wall box interior is substantially inaccessible. Stated differently, instead of using a conventional wall plate to complete the enclosure, the frame member 10 is used to prevent individuals from being shocked or electrocuted by concealing all electrical wiring under the frame 10 within the device wall box interior.

Thus, a frame enclosure lip 10-5 is disposed around the perimeter of the frame 10. The frame enclosure lip 10-5 is configured to substantially abut the wall surface 1 (not shown in this view) such that a front edge of a properly installed wall box does not substantially touch the rear side 10-2 of the frame 10. This is true even when old work boxes are deployed. Old work boxes, of course, have flanges that are mounted to the outer surface of the wall surface 1. The frame enclosure lip 10-5 raises the rear surface 10-2 overtop the work box to avoid any interference with the flanges and prevent the frame 10 from contacting the wall surface 1.

As shown, the frame 10 includes a frame opening 10-13 that has an interior serrated edge or lip 10-6 that is configured to mate with the modular alignment conductors 20 and/or the electrical wiring devices 30, 40, 42 or 50 in the manner disclosed below. Once the electrical wiring device and/or the modular alignment connectors are installed within the frame opening 10-13, the enclosure is completed. The interior serrated lip 10-6 extends along lateral portions of the frame opening 10-13 to adjoin a connector landing element 10-7 disposed at either end of the frame opening 10-13. The interior serrated lips 10-6 and the connector landing elements 10-7 extend perpendicularly around the entire frame opening 10-12 to form a rim or skirt that is inserted inwardly within the device box interior during installation. Accordingly, the region under the rear frame surface 10-2 between the outer enclosure lip 10-5 and the interior rim (i.e., serrated lips 10-6 and landing 10-7) is disposed over the wall surface 1. Once the wall box fasteners 10-10 are inserted into the fastener slots 10-12 and tightened, the interior of the device box is accessed via the frame opening 10-13. After device installation, however, the frame opening 10-13 is completely occupied by some combination of modular wiring devices (30, 40, 42 or 50) and/or modular alignment connectors 20 to thereby complete the enclosure. All of the wiring is under the frame assembly and cannot be accessed.

As embodied herein and depicted in FIGS. 2A-2D, perspective views of a modular alignment connector 20 in accordance with the present invention are disclosed. The modular alignment connector 20 is said to be modular because it adjusts and aligns the size of the frame opening such that various combinations of wiring devices (e.g., 30, 40, 42) disposed in a variety of spatial orientations are used to complete the frame opening 10-13 when they are installed therein.

FIG. 2A shows a front major surface 20-1 of the modular alignment connector 20 (when it is inserted within the frame opening 10-13). The front major surface 20-1 of the modular alignment connector 20 has a width of approximately 11.2 mm and a length of about 45 mm. One pair of the alignment connectors 20 are the same size as a one-module electrical wiring device. The front major surface 20-1 includes a front connector flange 20-6 which is configured to fit within the frame connector seat 10-14 when the connector is inserted within the frame 10. The modular alignment connector 20 also includes bending snap arms 20-3 and spacer tangs 20-4 disposed on either side of the connector 20. A spacer channel 20-5 is disposed between the snap arm 20-3 and the spacer tang 20-4. As their name suggests, the snap arms 20-3 are used to “snap” the alignment connector 20 into the frame opening 10-13. Subsequently, the spacer tang 20-4 is pressed into the spacer channel 20-5 to lock the modular alignment connector 20 into the frame opening 10-13. The locked snap arms 20-3 retain the alignment connector 20 within the frame opening 10-13 thereafter. Stated differently, when a spacer tang 20-4 is inserted into a channel 20-5, the snap arm 20-3 can no longer deflect inwardly and thus cannot be removed from place. The snap connect assembly (20-3, 20-4, and 20-5) is configured to withstand at least 50 foot-pounds of pulling force.

FIG. 2B shows the modular alignment connector 20 rotated 180° with respect to the view provided by FIG. 2A. The front stabilizing plate 20-6 and the rear connector flanges 20-7 form a connector channel 20-8 that is configured to grip the frame connector landing 10-7 (See FIGS. 1A-1B). The front stabilizing plate 20-6 is seated on the frame connector seat 10-14 when the alignment connector 20 is inserted into the frame opening 10-13. The purpose of the front stabilizing plate 20-6 is to help the connector 20 retain its position within the frame opening 10-13 by preventing it from being pushed inwardly and through frame opening 10-13.

FIG. 2C is a rear view of the modular alignment connector 20. This view shows a rear major surface 20-2 that is supported underneath by device stop elements 20-9. Like the serrated stop elements 10-60 of the serrated lip 10-6, the device stop elements 20-9 are configured to engage and mate with the device snap elements formed in the modular wiring device housing (See elements 30-2, 40-2, etc., depicted in FIG. 5) to complete the electrical enclosure. This snap-fit arrangement fixes the modular wiring device (30-2, 40-2) within the opening 10-13 such that it cannot move laterally or longitudinally within the frame opening 10-13 when snapped in place. Stated differently, the interior serrated lips 10-6 and device stop elements 20-9 serve to secure and align the electrical wiring device (30, 40, 50, etc.) within the frame opening 10-13.

FIG. 2D shows the modular connector 20 rotated 180° with respect to the view provided by FIG. 2C. When inserted into the frame opening 10-13, the rear stabilizing plate 20-7 bears against edges of the connector landing 10-7 (See FIGS. 1A-1B). Again, the front stabilizing plate 20-6 and the rear stabilizing plate 20-7 form a channel 20-8 that restricts the movement of the modular alignment connector 20 after being seated on the connector seat 10-14. As the connector 20 is moved to this seated position, bending snap arms 20-3 are deflected inwardly by the interior serrated lip 10-6 until they clear and snap back outwardly into the serrations. Again, the bending snap arms 20-3 prevent the connector 20 from sliding or moving out of its seated position.

FIG. 3 is a detail view of the modular alignment connector 20 depicted in FIGS. 2A-2D. This detail view clearly shows the bending snap arm 20-3, the spacer tang 20-4, and the spacer channel 20-5 formed therebetween. Again, if the space tang 20-4 is rotated downwardly into the channel 20-5, the snap arm 20-3 cannot deflect inwardly. This feature locks the connector 20 within the frame opening 10-13.

Referring to FIGS. 4A-4E, illustrative views showing installation details of the frame 10, modular alignment connector 20 and an electrical wiring device 40 are disclosed. As shown in FIG. 4A, one modular alignment connector 20 is locked into one end of the frame opening 10-13, while another alignment connector 20 is shown being inserted into the other end of the frame opening 10-13 (See arrow A). FIG. 4B shows the two connectors 20 locked into opposite ends of opening 10-13. In FIG. 4C, a wiring device 40 has been inserted between the modular alignment connectors 20. The back body 40-3 of device 40 is shown to be bearing against the spacer tangs 20-4 to thus prevent them from moving inwardly. Stated differently, the back body 40-3 prevents the spacer tangs 20-4 from being removed from the channel 20-5 such that the modular alignment connectors 20 cannot be removed from the frame once a wiring device 40 has been installed inside the frame opening 10-13. FIG. 4D is a side view that shows how device 40 was moved in the direction of the arrow “A” into the frame opening 10-13 during installation. FIG. 4E shows the device 40 fully installed within the opening 10-13.

As embodied herein and depicted in FIGS. 5A-5D, perspective views of the modular electrical wiring device types in accordance with the present invention are disclosed. FIG. 5A shows a one-module electrical wiring device 30. The user interface portion 30-1 has a width of approximately 22.5 mm and a length of about 45 mm. Thus, two one-module devices 30 placed side by side will complete a 45 mm×45 mm square. The back body 30-3 has snaps 30-2 at either end and is configured to fasten the device 30 to either the interior serrated lips 10-6 or to the device stop elements of the modular alignment connectors 20, depending on how the device is oriented with respect to frame 10 during installation (see FIGS. 6A-6G.)

FIG. 5B shows a two-module electrical wiring device 40. The dimensions of user interface portion 40-1 are approximately 45 mm×45 mm. The back body 40-3 has snap elements 40-2 disposed at either end. Like the snap elements 30-2 in FIG. 5A, the snap elements 40-2 are configured to fasten the modular device 40 to the interior serrated lips 10-6 or to the modular alignment connectors 20, depending on how it is oriented with respect to frame 10 during installation (see FIGS. 6D-6K.) The number of snaps provided in the various sides of the modular devices could be, but is not necessarily, equal in number. In an embodiment of the invention, one side of the device has two snap elements whereas an opposite side has only one snap element. Removal of a modular wiring device from the frame 10 is thus made easier by starting with the side with the single snap 40-2.

FIG. 5C discloses a “two-module front/three-module back” electrical wiring device 42. In this embodiment, the user interface portion 42-1 is about 45 mm×45 mm and the back body is approximately 67.5 mm in length. The back body 42-3 includes snap elements 42-2 disposed on either side thereof. The snap elements 42-2 are configured to fasten the device 42 into the frame opening 10-13 via the interior serrated lip portions 10-6.

FIG. 5D is a three module device that includes a user interface portion 50-1 that is approximately 45 mm×67.5 mm. The back body 50-3 includes snap elements 50-2 disposed on either side of the device 50. The snap elements 50-2 are configured to snap into the frame opening 10-13 by mating with the interior serrated lips 10-6.

Referring to FIGS. 6A-6N, illustrative views showing various combinations of modular electrical wiring devices installed within a single gang frame member 10 are disclosed. As inferred by the discussion immediately above, an unoccupied frame opening 10-13 (see, e.g., FIGS. 1A, 6C, etc.) has dimensions 45 mm (W)×67.5 mm (L). This allows the frame to accommodate various combinations of electrical wiring devices and modular alignment connectors 20 if their combined surface area equals 3,037.5 mm² (i.e., 45 mm×67.5 mm). This area corresponds, of course, to the front surface area occupied by the three-module wiring device 50.

In reference to FIGS. 6A-6B and 6H-6K, a pair of modular alignment connectors 20 is disposed at either end of the frame opening 10-13. As previously stated, the front major surface 20-1 of the modular alignment connector 20 has a width of approximately 11.2 mm and a length of about 45 mm. The pair of connectors 20 thus occupies the same amount of space that a one-module wiring device occupies. Stated differently, the modular alignment connectors 20 can be used with certain wiring devices, or certain combinations of wiring devices, when they are required to “complete the enclosure.” In FIG. 6A, for example, two one-module devices 30 are disposed lengthwise between the two connectors 20 to complete the enclosure. In FIG. 6B, two one-module devices 30 are disposed widthwise between the two connectors 20 to complete the enclosure. In FIG. 6H, a two-module device 40 is disposed upright between the two connectors 20 to complete the enclosure. In FIGS. 61 and 6K, a two-module device 40 is disposed sideways between the two connectors 20 to complete the enclosure. In FIG. 6J, a two-module device 40 is disposed upside down between the two connectors 20 to complete the enclosure. Thus, the electrical wiring devices of the present invention lend themselves to a variety of spatial orientations within the frame opening 10-13.

In FIGS. 6C-6G and 6L-6N, the system does not require the use of the modular alignment connectors 20. For example, FIGS. 6D-6G show various combinations and orientations of one-module wiring devices 30 and a two-module wiring devices 40. Of course, it is expected that these combinations should not require any alignment connectors 20 because a one-module device in combination with a two-module device occupies all of the three-module sized space provided by the frame opening 10-13.

FIG. 6L shows the frame opening 10-13 being fully occupied by one “two-module front/three-module back electrical wiring device 42, whereas FIGS. 6M and 6N show the frame opening 10-13 being fully occupied by one three-module sized device 50.

FIG. 7 is a perspective view showing a three gang frame member 10-30 with an illustrative combination of modular electrical wiring devices (30, 40, and 42) being installed therein. The three gang wall box 2 is installed within the wall surface 1 such that the frame enclosure lip 10-5 extends around the periphery of the frame 10-30 to abut the wall surface 1. Note that a multi-gang frame (10-20, 10-30, 10-40) employs “interrupted” gang separation ribs 10-31. The ribs 10-31 allow the modular alignment connectors 20 to be attached to the frame 10-30 inside individual gang openings 10-13 and also provide the interior serrated lip portions 10-6 for the wiring devices (30, 40, and 42) as before. However, the ribs are interrupted by a gap formed in an intermediate portion thereof that is advantageous during the wiring process. When the electrical wiring is being pulled through the opening 10-13 of the frame 10, the gap allows the installer to pull all of the wires through at one time without having to be concerned about whether the wires are properly matched to their respective frame openings 10-13. Moreover, each set of wires can be connected to their respective electrical wiring devices without interference by gang separation ribs that span the opening from top to bottom. By virtue of the gang separation ribs 10-31, once each set of wires is terminated to its respective wiring device, the electrical wiring devices with their respective sets of wires can be moved across the entire width of the multi-gang box and shifted into place in their respective installed locations.

FIG. 8 is a perspective view of a two gang frame member 10-20. Like the previous embodiment, the frame 10-20 includes gang separation ribs 10-21 which are also interrupted by a gapped portion in an intermediate portion thereof. The frame member 10-20 has a ground wire 10-9 attached to it in accordance with the present invention. In particular, the ground wire 10-9 is attached to the ground connection tab 10-8 that extends from the connector landing portion 10-7 of the frame 10 (See, e.g., FIGS. 1A-1B). As explained below, the wiring device modules (30, 40, 42 and 50) may be equipped with a self grounding terminal (See, e.g., ground terminal 40-10 at FIGS. 16A-16B) that is configured to contact the ground tab 10-8. Thus, a convenient electrical ground facility is provided by the present invention.

FIG. 9 is a perspective view of a three-gang frame member 10-30 in accordance with the present invention. Like the other multi-gang embodiments, frame 10-30 also includes gang separation ribs 10-31 which likewise include a gap in an intermediate portion thereof. Frame 10-30 is also equipped with a ground wire 10-9 in accordance with the present invention.

FIG. 10 is a perspective view of a four gang frame member 10-40 in accordance with the present invention. Frame 10-40 includes gang separation ribs 10-41 and with a ground wire 10-9. With respect to the previous embodiments, like parts are designated by like reference number numbers.

With respect to FIGS. 11A-11B, rear views of the three-gang and four-gang frame members 10-30 and 10-40 depicted in FIGS. 9 and 10 are disclosed. Note that in the multi-gang embodiments greater than two gangs, fastener slots 10-12 are only provided in the corner locations. In the interior gangs, the fastener slots 10-12 are replaced by fastener blanks 10-11. In addition, these rear views also show the manner in which the ground wire is connected to one of the ground connection tabs 10-8. Regardless of the frame size, i.e., only one ground wire 10-9 is needed per frame 10. One ground wire 10-9 need be bonded to a four-gang frame to provide ground connectivity between the premise ground and all of the devices (30, 40, 42, and/or 50) mounted on the frame 10. By eliminating the need for individual grounding wires, the self-grounding feature provides another efficient feature for the wiring and the device installation processes.

As embodied herein and depicted in FIGS. 12-14, exploded views of various aesthetic overlay assemblies 60 in accordance with the present invention are disclosed. Once the electrical wiring devices (30, 40, 42 or 50) and/or any modular connectors 20 are installed, each of the overlay assemblies 60 may be removed from the frame 10 by the homeowner without any risk of being exposed to hot electrical wiring or hot electrical components. Again, this is referred to above as frame 10 being used to “complete the enclosure.” Stated differently, the aesthetic overlay 60 is not used to complete the enclosure and is not used to prevent shock or electrocution. Because the component parts, materials or material thicknesses of the overlay assemblies 60 cannot adversely affect safety they can be selected from a broad range of materials including plastics, metals, wood, leather, wall paper, paint, laminated materials, and/or composite materials. Although the embodiments shown in FIGS. 12-14 are directed to single gang configurations, the principles set forth herein also apply to multi-gang configurations.

In reference to FIG. 12, the overlay assembly 60 includes an aesthetic overlay plate 60-1 that mates with an aesthetic support frame 60-2. Aesthetic overlay plate 60-1 shown in this view has a two-module aesthetic plate opening 60-10 that accommodates a pair of one-module electrical wiring devices 30, a two-module electrical wiring device 40 or a two-module front device 42 (See FIGS. 5A-5C). In an alternate embodiment, the aesthetic plate opening 60-10 is configured to accommodate a three-module electrical wiring device 50 (See FIG. 5D). A three-module opening can also accommodate any of the combinations of electrical wiring devices shown in FIGS. 6C-6G and FIGS. 6L-6N.

When a device combination employs the modular alignment connectors 20, the front major surface 20-1 of the connector 20 is recessed beneath the aesthetic overlay plate 60-1 and hidden from view by the overlay plate 60 after installation. In an alternate embodiment of the present invention, the connector front major surfaces 20-1 may be flush with the outer surface 60-1 of the overlay plate and in full view. In this embodiment, the front major surface 20-1 may be labeled or bear human readable indicia that identifies the purpose of the electrical wiring device or used to provide other useful information. The overlay plate 60-1 may be formed of from a broad range of materials including plastics, metals, wood, leather, wall paper, paint, laminated materials, and/or composite materials. In another non-limiting example, the plate 60-1 may also be formed from a material that can be painted to match the color of the wall surface 1.

The support frame 60-2 is configured to snap onto and off of the frame 10. The frame 10 includes ratcheting overlay snap devices 10-3 that adjustably mate with frame support catches 60-3. Even when the wall surface 1 is uneven, the adjustable ratcheting system described herein allows the frame 10 to fit snuggly against the wall surface 1. The overlay plate 60-1 includes a plurality of overlay snaps 60-6 that align with corresponding snap openings 60-5 in the support frame 60-2 to couple the aesthetic overlay plate 60-1 to the aesthetic support frame 60-2. In one embodiment of the present invention, there can be twelve overlay snaps 60-6 distributed around the periphery of the aesthetic overlay plate 60-1 to provide a secure bond between the plate 60-2 and the frame 60-2.

The aesthetic plate is coupled to the frame 10 when the plate 60 is disposed over the frame 10 such that the frame snaps 60-4 engage the side overlay snaps 10-4 disposed at intervals along the sides of the frame 10. When a user desires to change the aesthetic plate 60, a screw driver or a similar tool can be inserted between the overlay removal catch 60-7 and the overlay removal pry 10-3′. The leverage provided by the screw driver must overcome the snap-in bond between the frame snaps 60-4 and their respective side overlay snaps 10-4.

In reference to FIG. 13, an aesthetic overlay assembly 60′ in accordance with another embodiment of the present invention is disclosed. In this embodiment, the aesthetic overlay assembly 60′ includes a four-ply aesthetic overlay plate 60-1 coupled to the aesthetic support frame 60-2. The aesthetic overlay plate 60-1 includes a top finish layer 60-20 that is coupled to a metal backing plate 60-23 by a pressure sensitive adhesive 60-22. The backing plate 60-23 may be implemented using any suitable material such as a metallic material, a composite material or a suitable plastic material to provide rigidity to the otherwise flexible layers 60-20 and 60-22. The backing plate 60-23 includes plate posts 60-27 that are configured to mate with the frame support post openings 60-28 that are formed in the frame support plate 60-21. The frame support plate 60-21 also includes support posts 60-25 which are configured to mate with the post openings 60-26 formed in the aesthetic support frame 60-2.

FIG. 13 also shows a ground link 60-24 disposed between the aesthetic plate assembly 60-1 and the aesthetic frame 60-2. Briefly stated, one or more ground links 60-24 serve to connect the metal portions of the aesthetic frame assembly 60-1 to the frame 10 and by extension to the ground wire 10-9 and premise ground. Obviously, if the backing plate 60-23 is formed of a metallic material, the ground link 60-24 is needed to provide a conductive path from the plate 60-23 and the frame 10 to ground. Those skilled in the art will appreciate that the ground link 60-24 may be suitably employed in any of the embodiments described herein.

As described above, the aesthetic support frame 60-2 includes frame support catches 60-3 and frame snap catches 60-4. These elements are used to couple the aesthetic support frame 60-2 to the frame 10. In particular, the frame support catches 60-3 mate with the ratcheting overlay snaps 10-3 and the frame snap catches 60-4 mate with the side overlay snaps 10-4 to couple the aesthetic frame 60-2 to the frame 10.

In reference to FIG. 14, an exploded view of an aesthetic overlay assembly 60″ in accordance with yet another embodiment of the present invention is disclosed. In this embodiment, the aesthetic overlay plate 60-1 is implemented using a die-cast metal material. The die-cast metal may be finished with any suitable material in any aesthetically pleasing manner. The aesthetic overlay plate 60-1 is aligned and coupled to aesthetic support frame 60-2 by way of two interconnections. The first interconnection includes the aesthetic overlay support posts 60-31 which are configured to mate with the post openings 60-32 formed in the aesthetic frame 60-2. The second interconnection includes the so-called “robin tails” 60-33 which are configured to mate with the “robin tail nests” 60-34. During installation, the posts 60-31 are aligned to the post openings 60-32, and the robin tails 60-33 are aligned with the nests 60-34. In the next step, the posts 60-31 and the tails 60-33 are inserted into the post openings 60-32 and the nest openings 60-34, respectively. Finally, the tails 60-33, which at this point extend through the nest openings 60-34, are peened over an inside edge of the robin tail nests 60-34 such that the aesthetic plate 60-1 is secured to the aesthetic frame 60-2. FIG. 14 also includes a ground link 60-24 positioned between the aesthetic plate 60-1 and the aesthetic frame 60-2. Like the previous embodiment, one or more ground links 60-24 may be used to connect the metal plate 60-1 to the frame 10 and ground.

As embodied herein and depicted in FIGS. 15A-15D, various views of a modular electrical wiring device system 100 are disclosed. By way of non-limiting example, FIG. 15A shows a two-modular electrical wiring device 40 inserted into the frame 10, which is in turn, connected to the device box 2. Portions of the modular wiring device 40 and the frame 10 in its entirety are covered by the aesthetic overlay plate 60 (Shown in FIG. 12). FIG. 15B is almost identical, with the exception that the aesthetic overlay plate 60′ OF FIG. 13 is used. FIG. 15C shows the same arrangement using the aesthetic overlay depicted in FIG. 14. FIGS. 15A-15C show that each aesthetic overlay (60, 60′ and 60″) substantially abuts the adjacent wall surface 1 by virtue of the ratcheting overlay snap 10-3.

In reference to FIG. 15D, a cross-sectional view is provided to illustrate the relationship between the aesthetic overlay assembly 60, frame 10, and the wall surface 1. In this view, a three-module wiring device 50 is depicted for ease of illustration. The frame's serrated lip 10-6 is inserted within the wall box 2 opening to accommodate the wiring device 50 therewithin. The modular wiring device 50 includes snap elements 50-2 that mate with the serrated lip 10-6. The frame 10 is connected to the wall box 2 via fasteners 10-10 which extend through the raised front surface 10-1 portion of the frame 10 to provide clearance for the flange's of the old work box 2. The aesthetic overlay assembly 60 fits overtop the frame 10 and device 50, and includes an opening 60-10 that provides access to the user interface 50-1 portion of the wiring device 50. The aesthetic overlay frame 60-2 also includes the frame support catch 60-3 that engages the ratcheting overlay snaps 10-3. While this relationship was described above, it is seen clearly in this view; the support catch 60-3 includes grooves that mate with the ratcheting snaps 10-3 such that the overlay 60 can be adjusted upwardly and downwardly relative to the wall surface 1. Again, this feature of the present invention allows the aesthetic overlay 60 to be adjusted such that it can be substantially flush with the wall surface 1 even if the wall is rather uneven. Moreover, the wall box 2 may be a pre-existing wall box disposed in a pre-existing electrical distribution system or a new device box installed in a new installation.

As embodied herein and depicted in FIG. 16A, an exploded view of a two-module electrical wiring device 40 in accordance with the present invention is disclosed. In this example, the electrical wiring device 40 is shown as a full duplex receptacle. Those of ordinary skill in the art will understand that the present invention may embody other wiring devices such as GFCIs, AFCIs, mechanical switches, electronic switches, fan control devices, TVSS devices and the like. The modular device 40 includes a user-interface 40-1, which in this example embodiment is implemented by a cover member that has receptacle openings 40-16. The cover member 40-1 is shown to include a labeling flange 40-15. The labeling flange 40-15 is designed to overlay the frame 10 or a modular alignment connector 20, depending on how the electrical wiring device 40 is oriented during its installation in the frame 10.

Thus, the housing includes the cover 40-1, the back body member 40-3 and a separator 40-4 which is disposed therebetween. The separator 40-4, of course, provides a dielectric barrier between the hot, neutral and ground conductors to prevent short circuits. The hot and neutral conductors are not shown in this view because they are disposed under the shutter assembly 40-5. Reference is made to U.S. Pat. No. 8,044,299 and U.S. patent application Ser. No. 13/487,547, which are incorporated herein by reference as though fully set forth in their entirety, for a more detailed explanation of the shutter assembly 40-5. The ground connection is provided by the self-grounding terminal 40-10, which is described in greater detail below in the discussion pertaining to FIG. 16B. The full duplex receptacle 40 provides AC power to an electrical load via an AC power plug that is inserted into the receptacle openings 40-16. The blades of the AC plug are configured to mate with the hot, neutral and ground electrical contacts in communication with the openings 40-16.

In reference to FIG. 16B, a detail view of the self-grounding structure 40-10 depicted in FIG. 16A is disclosed. The self-grounding feature 40-10 includes an “L-shaped” ground strap 40-12 that accommodates the ground receptacle terminals 40-13 as well as the dual self-grounding terminal contacts 40-14. When comparing FIG. 16A with 16B, it becomes apparent that the self-grounding terminal contacts 40-14 are accessible via the ground access windows 40-11 formed in the back body member 40-3. As described above and shown in greater detail below, the self-grounding terminal contacts 40-14 are configured to engage the ground connection tab 10-8 or a portion of the serrated lip 10-6 (See FIGS. 1A-1B).

In reference to FIG. 17, a rear view of the modular system 100 illustrating the self-grounding structure 40-10 depicted in FIGS. 16A-16B is disclosed. The dual self-grounding terminal contacts 40-14 allow the wiring device (30, 40, 42 and 50) to be oriented in a variety of ways within the frame 10 while providing the self-grounding functionality. In this view, the frame opening 10-13 includes a two-module device 40 disposed between two modular alignment connectors 20. One of the dual self-grounding terminal contacts 40-14 engages the interior serrated lip 10-6 (on the left side of the frame 10) to provide ground connectivity between the grounding circuit of the electrical wiring device 40 and the frame 10. The ground connection is completed by the ground wire 10-9 being connected to the frame 10 and the premise wiring. Again, the ground wire 10-9 is bonded to ground connection tab 10-8 formed on connector landing 10-7. Of course, the other one of the dual self-grounding terminal contacts 40-14 that is disposed adjacent the modular alignment connector does not provide a ground path for obvious reasons (the modular alignment connector is non-conductive).

In reference to FIG. 18, a front perspective view of the system 100 depicted in FIG. 17 is disclosed. In this view, the electrical wiring device 40 is being inserted into the frame opening 10-13 such that one of the dual terminal connectors 40-14 will engage the interior serrated lip 10-6 of the frame 10 while the other engages the modular alignment connector 20. The hot and neutral openings 40-16 of the electrical wiring device 40 are aligned with the major longitudinal axis (i.e., the length) of the frame 10.

FIG. 19 illustrates the versatility of the system 100 because it shows the hot and neutral openings 40-16 of the electrical wiring device 40 being aligned with the major latitudinal axis (i.e., the width) of the frame 10. As before, the electrical wiring device 40 is being inserted into the frame opening 10-13 such that one of the dual terminal connectors 40-14 will engage the interior serrated lip 10-6 of the frame 10 while the other engages the modular alignment connector 20.

FIG. 20 is yet another perspective view of the system 100 that illustrates the versatility of the system 100. Like the previous embodiment, the hot and neutral openings 40-16 of the electrical wiring device 40 are aligned with the major latitudinal axis (i.e., the width) of the frame 10. Note however, that the frame opening 10-13 does not include any modular alignment connectors 20. This is because the system (in this Figure) will ultimately include a one-module device 30 (See, e.g., FIGS. 6D-6E) in combination with the two module device 40. In this configuration, both of the dual ground terminal contacts will engage portions of the frame 10. One terminal contact 40-14 will engage the interior serrated lip 10-6 while the other will engage the ground connection tab 10-8. The dual ground terminal 40-10 of the one-module device 30 (not shown in this view) will also engage the interior serrated lip 10-6 and the ground connection tab 10-8.

As embodied herein and depicted in FIG. 21, a four gang embodiment of the modular system 100 employing the self-grounding terminal 40-10 in accordance with the present invention is disclosed. In this embodiment, each of the four gang openings includes a two-module device 40 disposed between two modular alignment connectors 20. As described previously, the gang openings are separated by a gapped gang separation rib (i.e., the rib has a gap in the mid portion thereof for wiring efficiencies). The self-grounding terminal contact 40-14 of the right most wiring device 40 contacts the frame 10-40 along the right edge thereof. The self-grounding device contacts (40-14) of the other three wiring devices 40 obtain electrical continuity with the frame 10 by contacting their respective gang separation ribs 10-41.

As embodied herein and depicted in FIG. 22, another four gang frame embodiment is disclosed. In this alternative embodiment, the system 100 may be configured such that all four wiring devices 40 are individually connected to their respective ground wires 40-9 while the frame 10 itself is connected to a separate ground wire 10-9. This arrangement may be employed, for example, when the electrical wiring devices (30, 40, 42, and 50) include an isolated ground configuration. Those skilled in the art will understand that electrical wiring devices with isolated grounds are often used to provide power to loads that are sensitive to electrical noise. Instead of being grounded by way of wire 10-9, these devices have separate ground wires 40-9 that are connected together and bonded to a separate noise-free ground. Thus, the self-grounding feature of the present invention is not used when the electrical wiring devices are equipped with their own individual ground wires (40-9).

As embodied herein and depicted in FIG. 23, another three gang frame 10-30 embodiment of the present invention is disclosed. This embodiment is a variation of the three gang frames shown in, e.g., FIGS. 7, 9, and 11A. In this embodiment, the wall box mounting holes 10-12 are implemented as elongated slots that face the center of the frame. These elongated slots 10-12 permit the frame 10 to be rotationally leveled with respect to the horizontal before the fasteners 10-10 (not shown in this view) are tightened down to secure the frame to the wall box 2 (not shown in this view). The fastener holes are not provided at the center gang position because they would interfere with the aforementioned rotational alignment. Moreover, the corner fasteners suffice for securing the frame 10 to the wall box 2. The omission of those fasteners at the central gang locations is yet another example of how the invention provides efficiency during the wiring process. Stated differently, the top fastener opening 10-12 and the bottom fastener opening 10-12 are only provided for gang openings disposed between the lateral portion 10-15 of the frame and the gang separation rib 10-31. This translates to two gang, three gang and four gang implementations.

As noted previously, fastener location blanks 10-11 are provided in lieu of openings at interior gang locations. An installer may drill those out to enable wiring devices with mounting straps to be mounted there. Reference is made to U.S. patent application Ser. Nos. 12/861,619 and 13/029,846, which are incorporated herein by reference as though fully set forth in its entirety, for a more detailed explanation of electrical wiring devices that include mounting straps. In device of this type, the electrical wiring is terminated by a plug member that is inserted into a rear receptacle formed in the electrical wiring device. The plug connection is used instead of wiring terminals to provide electrical continuity between the electrical wiring device and the electrical distribution system. Of course, the present invention does not preclude the use of wiring terminals to provide electrical continuity between the electrical wiring device and the electrical distribution system.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening.

The recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.

All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not impose a limitation on the scope of the invention unless otherwise claimed.

No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. There is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. 

What is claimed is:
 1. A method comprising: providing a frame member configured to be disposed over a device wall box installed in a structure, the frame member including at least one frame opening having a lip member configured to substantially extend into an interior region of the device wall box, the at least one frame opening being further configured to substantially define a modular space; and providing at least one modular electrical wiring device configured to substantially conform to the modular space in accordance with at least one of a plurality of modular configurations, the at least one modular electrical wiring device being configured to include a plurality of attachment structures configured to mate with the frame member, the at least one modular electrical wiring device being configured to be disposed within the at least one frame opening in an orientation selected from a plurality of orientations including at least one first orientation and at least one second orientation, the at least one first orientation being substantially orthogonal to the at least one second orientation.
 2. The method of claim 1, wherein the step of providing the at least one modular electrical wiring device includes selecting the at least one modular electrical wiring device from a group of modular devices.
 3. The method of claim 2, wherein the at least one modular electrical wiring device is selected from a family of wiring devices that includes receptacles, protective devices, GFCIs, AFCIs, transient voltage surge suppressors, switches, dimmers, lighting control devices, occupancy sensing devices, and night light devices.
 4. The method of claim 2, wherein the group of modular devices includes at least one alignment device configured to mate with the frame member.
 5. The method of claim 3, wherein the at least one alignment device includes a first alignment device disposed at a first end of the at least one frame opening and a second alignment device disposed at a second end of the at least one frame opening, and wherein at least one modular electrical device is disposed between the first alignment device and the second alignment device.
 6. The method of claim 5, wherein the at least one modular electrical device includes two modular electrical devices disposed between the first alignment device and the second alignment device, the two modular electrical devices being disposed in the at least one first orientation or the at least one second orientation.
 7. The method of claim 6, wherein the plurality of orientations includes at least four orientations.
 8. The method of claim 4, further comprising the step of snapping the at least one alignment device in the at least one frame opening.
 9. The method of claim 1, further comprising the step of snapping the at least one modular electrical wiring device into the at least one frame opening in the at least one first orientation or the at least one second orientation.
 10. The method of claim 1, further including the step of providing an aesthetic cover plate, the aesthetic cover plate being configured to snap onto a peripheral portion of the frame member so that the frame member is substantially covered or concealed when a system comprising the frame member and the at least one modular electrical wiring device is mounted to the device wall box or mounted directly to the structure.
 11. The method of claim 10, wherein the aesthetic cover plate includes a linkage element configured to provide an electrical path to the frame member when the aesthetic cover plate is snapped onto a peripheral portion of the frame member. 